Apparatus for making filler materials

ABSTRACT

Apparatus in which yarn is automatically cut into predetermined lengths, rapidly fed into a container and made into spherical shapes by exposing said yarn to a spiral gas stream, and from which spherical shaped textile products, useful as filler materials for quilts, pillows, and the like, are automatically taken out of said container.

United States Patent Ogasawara et a1.

Dec. 2, 1975 APPARATUS FOR MAKING FILLER MATERIALS Inventors: Masafumi Ogasawara; Keio Hirai,

both of Otsu; Nobu Yamaguthi, Shiga; Akio Tsunekawa, Otsu; Tosiyuki Mizoguchi, Takatsuki; Shiro Nishiumi, Otsu, all of Japan Assignee: Toray Industries, Inc., Tokyo, Japan Filed: Aug. 26, 1974 Appl. No.2 500,699

U.S. Cl 19/148; 264/121 Int. Cl. D01G 25/00 Field of Search 28/1 R, 1.4; 19/.32, 144,

[56] References Cited UNITED STATES PATENTS 2,714,749 8/1955 Clark ct a1. 19/148 X 3,020,585 2/1962 Berthon ct al. 264/115 X 3,773,453 11/1973 Hino et a1. 28/l.4 X 3,783,060 1/1974 Goldsworthy et al 156/74 X Primary Examiner-Louis K. Rimrodt [57] ABSTRACT Apparatus in which yarn is automatically cut into predetermined lengths, rapidly fed into a container and made into spherical shapes by exposing said yarn to a spiral gas stream, and from which spherical shaped textile products, useful as filler materials for quilts, pillows, and the like, are automatically taken out of said container.

14 Claims, 12 Drawing Figures Sheet 1 of4 U.S. Patent Dec. 2, 1975 Sheet 2 of 4 US. Patent Dec. 2, 1975 US. Patent Dec. 2, 1975 Sheet 3 of4 3,922,756

US. Patent Dec. 2, 1975 Sheet 4 of4 3,922,756

Fig. 11(A) Fig. 11 13 APPARATUS FOR MAKING FILLER MATERIALS This invention relates to an apparatus for efficiently making filler materials having spherical shape and having characteristics similar to those of natural down.

Down, cotton and synthetic staple fibers have been used as filled for bedding products (such as quilts, pillows and so forth), wind jackets, sleeping bags, cushions, etc.

Among these materials, down shows excellent properties in bulkiness, softness, thermal insulation, compression recovery and moisture transmission. Products such as quilts filled with down conform well to the human body on which it is used, because of the draping property of down-filler products due to the mobility of down in quilts, etc.

Down absorbs and transmits water vapor, so that the excellent properties of down are retained even under damp conditions. Down is, however, susceptible to damage by insects and bacteria. On the other hand, so little down is produced in the world that its price is very high.

Cotton, compared with down, is inferior in bulkiness, softness and thermal insulation. Its compression recovery is relatively good, but not under damp conditions. Cotton is, however, used broadly for the above-mentioned products, because of its low price and because of its characteristics in absorbing and transmitting water vapor.

Synthetic staple fiber is made in a variety of compositions and geometrical shapes due to the wide variability in conditions for its manufacture, so that is properties (e.g. bulkiness, softness and thermal insulating property,) are controllable within some range. But, staple fiber of hydrophobic material has a problem as to transmission and absorption of water vapor. lts bulkiness and compression recovery are relatively good, but limited because of the geometrical shape of the fibers in comparison to that of down. Compared with those filled with down, products filled with cotton or conventional synthetic staple fiber do no conform well to the human body on which it is used and do not shown mutual migration even if they are used in opened and piled up form.

The present inventors have investigated the properties and the structure of down which is well known and widely used as an excellent filler material. The results of the investigation are summarized as follows.

A feather of down has a dendroid structure in which several tons of fine branches are developed from the end of a tiny stem or root, and each branch has many tiny twigs or protrusions along both sides of it, making itself barb-like. These branches are so fine and so tender that they bend very easily. Because of these structural features of a leaf of down, the feathers of down are prevented from intrusion or tangling of each element into or with other elements or groups of elements when down is compressed or stressed. Moreover, the branches are substantially bulky due to their barblike structure. Most down feathers are smaller than 25 mm in representative diameter. All of these features of the structure of down feathers help a mass of down to flatten with gentle resistance under compressive force and to recover easily fromsuch force; on the other hand, it allows each leaf of down to migrate within their mass.

In contrast, cotton, wool and synthetic staple fiber do not have a branch or barb'like structure so that their masses are easily flattened under compressive action and do not recover as does down. From these observations, the present inventors considered that filler materials used for quilts or wind jackets, etc., should have the exclusive or unintrusive property and the substantially three dimensional voluminous structure of natural down.

After many attempts, the conclusion was reached that structures and shapes of the type shown in FIGS. 11A and 11B provide such characteristics. In FIG. 11, a filamentary spherical body is shown, in which the filaments are running three dimensionally, arcuately disposed, and relatively densely concentrated near the outer surface of the body. The spherical filament mass is progressively less dense toward the interior of the body such that the body is hollow or substantially hollow. Because of these features of the bodies, the bodies are bulky, soft, have high compression recovery and are of high thermal insulation quality. Generally, the filaments making up the body are also intertwined to some extent.

This matter is already described in our prior U.S. patent application, Ser. No. 324,142, filed Jan. 16, 1973, assigned to the assignee hereof.

The general object of this invention is to provide a novel and compact apparatus for making filler materials of the type described in the aforementioned patent application at low cost.

BRIEF SUMMARY OF THE INVENTION This and other objects are met by an apparatus including a yarn feeding device, yarn transfer and accelerating means, yarn cutting means for cutting preselected lengths of yarn pieces, round bottom containers for receiving the cut yarn pieces, gas impingement means for swirling said pieces in said container into spherical products and product removal means (usually a bottom gas jet and removal channel.)

Further objects and details of this invention will be apparent from the following description and drawings, in which:

FIG. 1 is a schematic illustration of one embodiment of the apparatus of the present invention;

FIG. 2 is a partial enlarged view of the apparatus shown in FIG. 1;

FIG. 3 illustrates a yarn feeding device intermittently feeding a filamentary yarn in an apparatus of the type shown in FIG. 1;

FIGS. 4 6 illustrate yarn storing means provided be tween a yarn feeding device and yarn transfer means in the apparatus of the type shown in FIG. 1. FIG. 4 illustrates an embodiment in which a belt is disposed in a horizontal direction. FIG. 5 illustrates an embodiment in which the belt of FIG. 4 is disposed in a perpendicular direction. FIG. 6 illustrates yarn storing means without having a guide for removing the yarn;

FIG. 7 is an enlarged perspective view of an embodiment of the apparatus of FIG. 1 in which the distance between a yarn cutter and a receiving container is shorter than the length of the cut filamentary pieces;

FIG. 8 is a drawing showing the relation between a receiving container and gas ejecting means;

FIG. 9 is a drawing showing the relation between a container and a take-out device;

FIG. 10 illustrates another embodiment of a container and gas ejecting means;

FIG. 11 shows a spherical textile product obtained by an apparatus according to this invention, in which FIG.

11A shows the complete product and FIG. 11B showns the same product in cross-section.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS OF THE INVENTION An apparatus, in accordance with the present invention, for efficiently producing a spherical textile product, as shown in FIG. 11., should satisfy the following requirements.

a. At first, as a yarn to be used, a filamentary yarn, especially a multifilamentary yarn is preferable and it is necessary that the apparatus open such yarn into respective monofilaments so as to be apt to form spherical shapes.

b. In order to make the size of spheres about the same, it is necessary that the apparatus include a yarn cutter so that the length of filamentary pieces for making speheres is about the same. (When mis-cutting occurs, it is not possible to obtain a satisfactory spherical textile product.)

c. Filamentary pieces must be rapidly fed to and received in a round bottom container until the container transfers to the next position. To that end, the speed at which filamentary pieces are fed to the container is made higher than the yarn feed speed. When fed to and received in the container rapidly, the filamentary pieces collide with the container and opening of the filaments is promoted.

d. It is necessary to make the structure of the textile products formed in spherical shapes strong so as to stabilize the shapes. When intertwinement among filaments is insufficient for this purpose, it is necessary to further reinforce this textile product, such as by chemical or heat adhesion.

One embodiment of the apparatus satisfying the aforesaid requirements is specifically shown in FIG. 1.

In FIG. 1, a filamentary yarn 1 is continuously fed at a constant speed to yarn transfer means by a yarn feeding device 2 from a yarn supply 3. Yarn transfer means 10, which takes the yarn from yarn feeding device 2 and forwards it toward tubular guides 12 and 13, described below, with acceleration induced by the suction and jet action of air nozzle 11 may also include a pair of rollers rotated at extremely high speed relative to the yarn feeding rollers 2. In the embodiment shown in FIG. 1, air nozzle 11 has two functions, that of suction and that of jetting of the yarn by the air stream from air nozzle 11. This air stream sucks the filamentary yarn 1 forwarded from the yarn feeding device 2; at the same time, said yarn is accelerated by the highspeed air stream and forwarded to an upper tubular guide 12 and a lower tubular guide 13. During that period, said yarn undergoes a yarn opening step (spreading of the individual monofilaments of the multi-filament yarn) and this is induced by the jet. A yarn cutter is provided between the upper tubular guide 12 and the lower tubular guide 13 and is operated to cut intermittently the filamentary yarn into filamentary pieces 1 (seen in the cut-away portion of the tubular guide 13), that are then received in a round bottom container 14. The length of the filamentary pieces 1 corresponds to the length of the filamentary yarn 1 which passes the position where the cut is made by yarn cutter 15 between cuts. The yarn cutter 15 shown herein comprises, as one example, an electric hair clipper 16 and a rotary guide 17. Said rotary guide 17 passes through a gap between the upper tubular guide 12 and the lower tubular guide 13, pressing the filamentary yarn to the blades of the clipper 16 to cut the filamentary yarn. As the yarn cutter in the present invention, cutters of various shapes and types, as used generally in the fiber industry, may be used.

There are a plurality of said containers 14, each of which is mounted on a disc 18 connected to an intermittent driving structure 19. Containers 14 mounted on disc 18 are so arranged that the opening of each of the containers faces the outlet of the lower tubular guide 13 at a specified position, such that filamentary pieces 1' cut by the operation of the yarn cutter 15 are received therein. As each container 14 has received a quantity of cut fibers l, the intermittent drive structure 19 is operated to bring the next container 14 below the outlet of the lower tubular guide 13; at the same time transferring the container 14 containing the filamentary pieces 1 to a position facing gas ejecting means 20. At this position, the filamentary pieces 1 are subjected to the action of an air stream fed from gas ejecting means 20, which swirls in container 14, causing the filamentary pieces 1 to be gradually formed into spherical textile products, with fibers more densely concentrated near the surface thereof and less densely concentrated inwardly from the surface with an interior which is hollow or substantially hollow. The gas ejecting means 20 consists of a small compressor 21 and conduits 22. Pressurized gas fed from the compressor 21 is ejected from the tips of the conduits 22 into the containers 14 at cetain position in the course of rotation of disc 18. The tip of each of the conduits 22 is adapted to slide eccentrically from the center axis of the container 14 located below said tip. This sliding motion imparts rotation to the filamentary piece or spherical textile product in containers 14. The pressurized gas ejected from the conduits 22 may be continuously fed; however, when said gas is fed intermittently or pulsatingly, there is a higher probability of imparting rotation or three dimensional rotation facilitating the production of better products. When the filamentary pieces 1 are formed sufficiently into spherical shapes by the action of the pressurized gas for a certain time, the textile products thus obtained are taken out from the container and transferred to the next step. However, when the filamentary pieces are not formed sufficently into spherical shapes, said pieces are ejected with a pressurized gas at the position to which it is subsequently transferred. This procedure is repeated until the filamentary pieces are formed sufficiently into spherical shapes, and the resulting spherical textile products are taken out from the container 14 by takeup means 23 and transferred to the next step. The takeout means 23 shown in FIG. 1 consists mainly of a nozzle 24 jetting an air stream from the bottom of the container 14 and a direction changer 25 or channel having a shape covering the upper side of the containers 14 and extending further externally. An air stream jetted from the nozzle 24 passes through holes bored on the bottom of container 14, blowing the spherical textile products upwardly and transferring said products out of the appratus via the direction changer 25. The emptied container is then rotated back to its initial position by the operation of disc 18, and the same operations are repeated.

In the apparatus shown in FIG. 1, the operation of the yarn cutter 15 and the operation of the disc 18 by the intermittent moving structure 19 are so adapted as to correspond 1:1. Namely, the yarn cutter l5 and the intermittent moving structure 19 are supplied with power from a common axis 27 driven by a motor 26.

FIG. 2 is an enlarged view of the yarn cutter l5 and associated elements of the apparatus shown in FIG. 1, modified however in that clipper 16 is positioned further from the central axis of tubular guides 12 and 13 so that as the filamentary yarn l is drawn near the blade of the electric hair clipper 16 by the rotary guide 18, newly fed filamentary yarn 1 passes the back surface of rotary guide 17, being forwarded into the lower tubular guide while forming a U-shaped by the jet gas of the yarn transfer means 10. When the yarn cutter operates and the filamentary yarn 1 is cut, the tip side of the filamentary yarn becomes filamentary pieces 1 The tip of the U-shaped hanging filamentary yarn is also rapidly forwarded into the lower tubular guide 13 by the jetted gas and the U-shape is made linear.

Upon operating the yarn cutter, it is necessary to note that the filamentary yarn may not slide on the rotary guide and that the U-shaped hanging part of the filamentary yarn may not be cut. The width of the rotary guide, r.p.m. of the rotary guide 17 and relative position of the electric hair clipper to the upper tubular guide and the lower tubular guide must be selected to preclude such a hang-up.

A reciprocatory guide may be used in place of the rotary guide. In this case, the back surface of the reciprocatory guide form a gentle-sloping curve, so that, when the reciprocatory guide come back to the fomer position, the filamentary yarn passing through the tubular guide can easily slid on the gentle-sloping curve.

FIG. 3 shows still another modification of FIG. 1. In the embodiment of FIG. 3, an intermittently driven yarn feeding device 2A consists of a driven roller 33 and a driving roller 34. The filamentary yarn 1 to be fed is wound up around the driven roller 33. Said driven roller 33 is pressed against the driving roller 34 rotating intermittently at a cetain speed. Accordingly, the filamentary yarn is forwarded to the yarn transfer means only while the driven roller rotates.

Because of this, transfer of the filamentary yarn to the aforesaid upper tubular guide 12 is carried out only intermittently. When the yarn cutter is operated in conformity with this yarn feed timing, it results in the forwarding of filamentary piece of a precisely predetermined length to the container 14. It goes without saying that the operations of the disc 18 and the operations of the yarn cutter 15 also correspond with one another.

FIG. 4 shows another modified embodiment of the apparatus shown in FIG. 1 in which yarn storing means, for storing a certain length of yarn, is provided between the yarn feeding device 2 and the yarn transfer means 10. In FIG. 4, the filamentary yarn 1 is continuously taken out at a certain speed from the package 3 and fed into the yarn storing means 4. While the filamentary yarn l is fed into the yarn storing means 4, the filamentary yarn at the fixed guide b, comprising the outlet of the yarn storing means 4 is practically at rest. The yarn storing means in the embodiment shown in FIG. 4, consists of two timing pulleys 5, 5, a timing belt 6, at least three running guides, 8, 8a, 8b mounted on on the timing belt 6, and a removing guide 7. The fed filamentary yarn 1 is hooked at a position directly below fixed guide A by running guide 8, transferred leftward in accordance with the motion of the timing belt 6 and removed from the running guide 8 at a position directly above fixed guide B by the yarn removing guide 7. In this case, when the running speed of the timing belt is set up at about one half of the yarn feed speed of the yarn feeding device, almost all of the fed filamentary yarn is transferred leftward by the running guide 8, roughly to the position A of guide 8a and substantially that length of the filamentary yarn 1 is stored in the yarn storing means; as a result, the filamentary yarn is at almost standstill at the outlet guide B of the yarn storing means 4. The filamentary yarn 1 at the outlet side of the yarn storing means 4 is always held by the sucking action of the yarn transfer means 10. When the filamentary yarn 1 is removed at position A (the position of running guide 8a in FIG. 4) the filamentary yarn stored in the yarn storing means 4 is released from restriction; therefore said yarn is engaged in the jet stream of the yarn transfer means, being rapidly forwarded to the upper and lower tubular guides 12, 13 while fibers constituting said yarn are opened and kept at an approximately linear state in these tubular guides. During the process, the yarn returns to the shortest distance connecting the yarn feeding device 2 and the yarn transfer means 10. When the running guide 8 comes to the point B, again (the position of running guide 8b in FIG. 4) the yarn storing means begins to operate again. The yarn cutter operates when the next yarn storing cycle is started and the filamentary yarn is almost at a standstill. As in the unmodified form of the apparatus, the cut filamentary pieces are engaged in the jet air stream and are rapidly fed to and received in container 14.

By repeating such operations as mentioned above, it is possible to feed continuously filamentary pieces of a predetermined length to container 14.

The length of the filamentary yarn stored by one operation of the yarn storing means is the sum of distances between positions shown in FIG. 4. Namely, it is a value obtained by deducting the length a -B b from the length a A b. When it is so set up that the filamentary piece is removed from running guide 8 at position A while the next running guide 8 is at position B, the length of yarn stored in each place will correspond with the length of one filamentary piece. It goes without saying that in the apparatus shown in FIG. 4, the yarn storing means 4, the yarn cutter 15 and transfer of the containers 14 driven by the intermittent moving structure 19 are adapted to operate by power from one driving system by a motor 26 so that the respective operations always correspond to each other.

FIG. 5 illustrates another form of yarn storing means which may be used in the apparatus of the present invention. In contrast to the yarn storing means shown in FIG. 4, in which transfer of the running guide 8 is so adapted as to be at a right angle with the yarn feed direction, the yarn storing means 4a of FIG. 5 is disposed generally parallel to the yarn feed direction of the filamentary yarn and is equipped with two running guides 8. The function and effect of said yarn storing means 40 are the same as those in FIG. 4. In this case, it is necessary to carefully select the locations of the various elements so that the filamentary yarn released from the yarn storing means may not coil round and be hooked by fixed guides a, b and the timing belt. The other elements corresponding to those shown in FIG. 4 are given like reference numerals also in FIG. 5.

FIG. 6 illustrates still another form of the yarn storing means, in which only one running guide 8 is provided in the timing belt. It is so adapted that the filamentary yarn does not substantially transfer to the yarn transfer means 10 while the running guide hooking the filamentary yarn rises. While the running guide 8 descends, it

is possible to suck the filamentary yarn at a speed twice as fast as the yarn feed speed to the yarn transfer means therefore, the yarn cutter may be operated while the running guide 8 rises.

In the embodiments shown in FIGS. 4 6, the speed of the running guide 8 is made to be in accord with the operating speed of the yarn feeding device; however, the speed of the running guide 8 is not limited thereto.

The various forms of apparatus shown in FIGS. 1 6 may efficiently produce spherical textile products to become filler materials.

The apparatus shown in FIG. 1 is designed for cutting a continuously fed filamentary yarn, in which the length of filamentary pieces may be changed by adjusting the operating timing of the yarn cutter. Because the apparatus of FIG. 1 has no yarn storing means, it is possible to make the entire apparatus of FIG. 1 small; at the same time, maintenance and checking of the apparatus is facilitated.

On the other hand, the various forms of apparatus shown in FIG. 3 6 are designed for feeding the filamentary yarn intermittently to the yarn transfer means; therefore, cutting is easy because it is possible to operate the yarn cutter while the filamentary yarn is almost at a standstill. In addition, these designs are advantageous in that the distance between the yarn transfer means and the container may be shortened. And that, even though the operating timing of the yarn cutter fluctuates to some extent, the length of the filamentary pieces is not greatly affected; therefore, it is possible to raise the yarn feed speed.

FIG. 7 is a drawing for the purpose of demonstrating a phenomenon brought about when the length of the lower tubular guide is shorter than the length of the filamentary pieces. In this case, the tip of the filamentary yarn is forwarded to the container 14 before it is cut, and the other end of the filamentary yarn is held up in the tubular guide. This results in the forward tip of the cut filament piece entering container 14 getting intertwined in the container before the tail enters the container. Such filamentary pieces do not form uniform, spherical products; hence good products are unlikely to be obtained. Therefore, it is desirable that the entier cut filamentary piece enter the container without time lag or almost instantaneously. In FIG. 7, air holes 30, 31 are provided in the lower tubular guide 13 and the container 14. By these air holes, it is possible to control the jet stream from the yarn transfer means. In this manner, the entanglement of the tips of the filamentary pieces with previously cut pieces may be minimized; further, the filamentary pieces do not jump out under the action of the jet stream and are easily accomodated in the container.

FIG. 8 illustrates how a gas fed from the conduit 22 is ejected toward the filamentary piece that is being formed into a spherical shape. The conduit 22 may be disposed at a position away from the center line of the container 14 or may be directed toward the center line so long as its axis (or the extension thereof) crosses the center line at an angle other than a right angle. This tends to rotate the filamentary piece 29 that is being formed into a spherical shape. Air holes 31 control a gas fed from the conduit so that the filamentary piece 29 that is being formed into a spherical shape may not jump out from the container 14, at the same time, promoting rotation of the filamentary piece 29.

FIG. 9 is an enlarged view of the main parts of the take-up device 23, showing particularly how the spherically shaped textile product 32 is taken out. When an air stream is ejected from nozzle 24, provided at the lower side of container 14, the air stream passes through the air holes provided at the lower side of the container 14, colliding with the textile product 32. The textile product 32 floats upward in that air stream from the nozzle 24 and is taken out from the container 14 to the outside.

While this invention has been explained with reference to specific apparatus, it should be understood that other embodiments of the present invention and, alterations following the gist of the present invention as indicated herein are included in the scope of the present invention.

For example, FIG. 10 shows a structure in which container l4 and conduit 22 are integral; other alternatives include a structure in which the upper tubular guide 12 is not used and the yarn cutter 15 is provided between the yarn transfer means 10 and the lower tubular guide 13, or a structure in which the respective operating parts are operated by separate driving devices. The receiving container 14 may be made a structure in which the container does not move intermittently, but passes below the lower tubular guide and through the take-up means or makes a smooth reciprocating motion between the two. However, in this case, when the filamentary yarn is cut by the yarn cutter, at the moment the cut filamentary pieces are received in the container, the container should have at least 40% of its top opening facing the tubular guide outlet so as to be able to accomodate the filamentary pieces therein. And at this time, the various mechanical operations should be synchronized with the timing of the container passing below the tubular guide. Moreover, in order to promote the opening of the filaments, an opening means, for instance a means to produce static electricity in the yarn, can be used. Or in the case of filament being apt to be attracted to metal parts, such asthe tubular guide or container by the force of static electricity, a static electricity eliminating means also can be used.

As a filamentary yarn to be fed to an apparatus according to the present invention, ordinarily a multifilamentary yarn of a single component is used; however, not only a continuous filamentary yarn, but also a somewhat less twisted spun yarn having a very long fiber length may be used.

If one uses a filamentary yarn consisting of at least two components different in melting point or softening point (for example, a mixed or composite yarn), it is possible to obtain a textile product stable in shape by feeding a hot gas, partly melting the low softening point fiber, to the ejecting means. Further, it is also possible to feed a gas to which an adhesive and an oiling agent have been sprayed from the ejecting means. Furthermore, it is also possible to jet the necessary amount of the low softening point fiberfrom the ejecting means in advance in the preceding stage and then eject a hot gas.

A textile product obtained by the apparatus of the present invention and removed from the take-out means may be transferred, via a conveyor transfer device or air transfer device, to a separate chemical treating device, such as for example a device for imparting a surface smooth agent, an oiling agent, an antistatic agent and a softening agent, and a packing device for filling the textile product into final products such as quilting, pillow covers, and insulated jackets, etc., thus further promoting time saving and efficiency through continuous multi-step processing. As yarn transfer means in the present invention, means of any structure will do insofar as it functions by sucking and accelerating a yarn, and the arrangement of said means is not limited to the positions shown in FIG. 1 and FIG. 4. It is conceivable to provide such transfer means at the lower part of the receiving container 14 as occasion demands. And the tubular guide need not be divided into two parts.

Example 1 Using the apparatus shown in FIG. 1, a 75 D 12 F polyethylene terephthalate multifilament yarn was fed at a constant speed of 60 m/min. Compressed air at 4 kg/cm gauge was used in the yarn transfer means 10. With the upper tubular guide cm long and the lower tubular guide 100 cm long, the rotary guide was operated at 60 R.P.M. with the operation frequency of the intermittent moving structure, 60 times/min. On the side wall and bottom wall of the container 14, a total of 40 air holes were bored. Six conduits were provided for the container 14 and compressed air was intermittently fed. The formed textile products were taken out by nozzle 24 and the direction changer 25 to a bag connected to the direction changer. The appearance, extemally and in section, of the obtained textile product are shown in FIG. 11 A and B, respectively. As seen in these figures, the fibers in this product are more densely concentrated near the outer surface of the spherical body and less densely concentrated inwardly thereof with the interior region void or substantially void such that the spherical body is hollow for all practical purposes.

Example 2 The yarn storing means shown in FIG. 4 was added to the apparatus of Example 1 and the resultant apparatus was so adapted as to make the one-time storing amount 100 cm. The operating conditions were the same as those in Example 1. The obtained textile product was almost the same as that of Example 1.

Example 3 To the gas ejecting means in the apparatus shown in FIG. 1, 10 conduits were fitted, from four conduits on the side of the take-up means, from which hot air at 220C. was ejected. The rest of the operating conditions were the same as in Example I.

The filamentary yarn feed was a 100 D 15 F sheathcore type composite yarn, the core component of which was a high melting point polyethylene terephthalate (softening point 260C) which was covered with a sheath component consisting of a low melting point polyester (softening point 175C) obtained by copolymerizing terephthalic acid and isophthalic acid with glycol (1,4-butanediol) (composite ratio of the high melting point polymer tothe low melting point polymer, 80/20).

The product had an adhering point at which the fibers could be adhered by fusion. By adding an adhesive to said product and thereafter heating and drying it, a further product was obtained which exhibited excellent shape, retentivity against compression, shearing deformation and attrition (mechanical break down due to friction). When this textile product, after adhesion 10 treatment, was used in a quilt, the quilt exhibited characteristics very close to those of a down-filled product.

We claim:

1. An apparatus for making a filler material comprising a. a yarn feeding and cutting device,

b. a tubular guide,

c. yarn transfer means arranged for taking up the cut yarn filaments and forwarding them along said tubular guide,

d. a plurality of movable containers each of which has a curved inner surface and is adapted to be moved in a manner to be disposed in a position facing the outlet of said tubular guide, means for moving said containers in succession to and from said position,

e. gas jet means for forming the cut yarn filaments into a shperical shape of each of said containers, and

f. means for taking the spherically shaped products out of said containers.

2. An apparatus as defined in claim 1, wherein a yarn transfer means is provided upstream of said cutting device which consists of a pneumatic yarn suction and ejecting device.

3. An apparatus as defined in claim 2, wherein a yarn storing means temporarily storing the yarn fed continuously is provided between said yam feeding means and said yarn transfer means.

4. An apparatus as defined in claim 2, wherein movements of said yarn feeding device, yarn transfer means, yarn cutter, and containers are respectively so adjusted that successive cut yarn of preselected length is fed into successive empty containers.

5. An apparatus as defined in claim 4, wherein each said container has a cross-sectional area opening, and wherein at least 40% of the cross-sectional area opening of the container faces the outlet of the tubular guide when said yarn cutter is operated.

6. An apparatus as defined in claim 1, wherein said yarn feeding device feeds the yarn intermittently.

7. An apparatus as defined in claim 1, wherein said yarn feeding device feeds the yarn continuously.

8. An apparatus as defined in claim 1, wherein gas, heated to a temperature sufficient to fuse a part of the filament and make it cohesive, is used as part of said gas ejecting means.

9. An apparatus as defined in claim 1, wherein said each container has several apertures on its shell.

10. An apparatus as defined in claim 1, wherein said tubular guide is divided into two pieces and said yarn cutting device is disposed between said pieces.

11. An apparatus as defined in claim 1, wherein said containers are moved continuously by a driving means.

12. An apparatus as defined in claim 1, wherein said containers are moved intermittently by an intermittent driving means.

13. An apparatus as defined in claim 12, wherein the movement of said intermittent driving equipment is synchronized with the movement of said yarn cutter.

14. An apparatus as defined in claim 1 wherein said means is connected to feed a conveyor apparatus for conveying said spherical shaped textile products. 

1. An apparatus for making a filler material comprising a. a yarn feeding and cutting device, b. a tubular guide, c. yarn transfer means arranged for taking up the cut yarn filaments and forwarding them along said tubular guide, d. a plurality of movable containers each of which has a curved inner surface and is adapted to be moved in a manner to be disposed in a position facing the outlet of said tubular guide, means for moving said containers in succession to and from said position, e. gas jet means for forming the cut yarn filaments into a shperical shape of each of said containers, and f. means for taking the spherically shaped products out of said containers.
 2. An apparatus as defined in claim 1, wherein a yarn transfer means is provided upstream of said cutting device which consists of a pneumatic yarn suction and ejecting device.
 3. An apparatus as defined in claim 2, wherein a yarn storing means temporarily storing the yarn fed continuously is provided between said yarn feeding means and said yarn transfer means.
 4. An apparatus as defined in claim 2, wherein movements of said yarn feeding device, yarn transfer means, yarn cutter, and containers are respectively so adjusted that successive cut yarn of preselected length is fed into successive empty containers.
 5. An apparatus as defined in claim 4, wherein each said container has a cross-sectional area opening, and wherein at least 40% of the cross-sectional area opening of the container faces the outlet of the tubular guide when said yarn cutter is operated.
 6. An apparatus as defined in claim 1, wherein said yarn feeding device feeds the yarn intermittently.
 7. An apparatus as defined in claim 1, wherein said yarn feeding device feeds the yarn continuously.
 8. An apparatus as defined in claim 1, wherein gas, heated to a temperature sufficient to fuse a part of the filament and make it cohesive, is used as part of said gas ejecting means.
 9. An apparatus as defined in claim 1, wherein said each container has several apertures on its shell.
 10. An apparatus as defined in claim 1, wherein said tubular guide is divided into two pieces and said yarn cutting device is disposed between said pieces.
 11. An apparatus as defined in claim 1, wherein said containers are moved continuously by a driving means.
 12. An apparatus as defined in claim 1, wherein said containers are moved intermittently by an intermittent driving means.
 13. An apparatus as defined in claim 12, wherein the movement of said intermittent driving equipment is synchronized with the movement of said yarn cutter.
 14. An apparatus as defined in claim 1 wherein said means is connected to feed a conveyor apparatus for conveying said spherical shaped textile products. 